1、 Daily inspection and monitoring

1. Visual inspection
   • Damage and cracksRegularly inspect the outer sheath of the cable for scratches, cracks, or aging, with particular attention to the areas with the smallest bending radius (such as the ends of the drag chain).
   • Deformation and distortionObserve whether the cable is deformed due to excessive bending or stretching. If local bulging or flattening is found, it should be stopped immediately and replaced.
   • joint loosesCheck if the connection between the cable and the equipment (such as plugs and sockets) is loose or detached to prevent poor contact from causing signal interruption or short circuit.
2. Performance Test
   • Electrical performanceUse a multimeter to check the insulation resistance and conductivity of the cable, ensuring that there are no short circuits or open circuits.
   • signal transmissionFor cables that transmit data or high-frequency signals, professional equipment must be used to test the signal attenuation rate to ensure stable transmission quality.
3. Monitoring of operating environment
   • Temperature and HumidityEnsure that the operating temperature of the cable is within the range of -40 ℃ to+90 ℃, and the humidity does not exceed 85%, to avoid high temperature accelerating insulation aging or low temperature causing brittleness.
   • mechanical stressCheck if the bending radius of the drag chain meets the minimum bending requirements of the cable (usually 6-10 times the outer diameter of the cable) to prevent excessive bending and damage to the internal conductor.

2、 Usage standards and operating precautions

1. Avoid excessive bending and stretching
   • Bending radius controlSelect the appropriate drag chain according to the cable model, ensuring that the bending radius is not less than the minimum allowable value of the cable. For example, the minimum bending radius of a highly flexible drag chain cable may be 7.5 times the outer diameter.
   • Stretching force limitationThe tensile force of the cable in the drag chain shall not exceed 20% of its rated value to avoid conductor breakage or insulation layer peeling due to tension.
2. Prevent twisting and entanglement
   • Installation directionEnsure that the cables are arranged in parallel within the drag chain, avoiding crossing or entanglement. If multiple cables need to be run in parallel, they need to be fixed in place using separators.
   • Rotation compensationFor situations that require rotation (such as robot joints), use drag chains or cables with rotation compensation function to prevent the accumulation of torsional stress.
3. Load and speed matching
   • Load limitChoose the appropriate current load based on the cross-sectional area and material of the cable to avoid overheating and accelerated aging caused by overload.
   • running speedControl the speed of the drag chain movement (usually not exceeding 5m/s), and use highly flexible and wear-resistant specialized cables for high-speed movement.

3、 Cleaning and Storage

1. regular cleaning
   • Cleaning of outer sheathWipe the surface of the cable with a clean soft cloth to remove impurities such as oil and dust. If the pollution is severe, neutral cleaning agents (such as soapy water) can be used for cleaning, but they must be wiped dry immediately.
   • internal cleaningFor open drag chains, regularly clean the internal debris (such as metal shavings and plastic particles) to prevent scratching the cables.
2. Proper storage
   • Environmental RequirementsStore the cables in a dry, ventilated, and non corrosive gas environment, avoiding direct sunlight or rain. The recommended relative humidity is ≤ 70%, and the ambient temperature is 0-40 ℃.
   • Winding methodWhen stored for a long time, cables should be coiled with a large radius (≥ 15 times the outer diameter) and hung for storage to avoid deformation caused by flat placement.
   • moisture and mold proofFor cables that are prone to moisture (such as paper insulated cables), they can be wrapped in moisture-proof paper or plastic film and regularly ventilated for inspection.

4、 Professional maintenance and replacement

1. Regularly replace vulnerable parts
   • outer sheathIf there are cracks or perforations in the outer sheath, it should be replaced immediately to prevent moisture from entering and causing a short circuit.
   • Conductor and insulation layerFor cables with broken internal conductors or aging insulation layers, they need to be replaced as a whole to avoid potential safety hazards caused by local repairs.
2. Professional testing and calibration
   • Withstand Voltage TestConduct a voltage withstand test every six months (usually 2.5 times the rated voltage for 5 minutes) to ensure that the insulation performance meets the standard.
   • Mechanical performance testingFor high-frequency cables, their fatigue resistance performance (such as bending test) should be regularly tested to ensure that they meet the usage requirements.
3. Spare Parts Management
   • inventory managementReserve an appropriate amount of spare cables according to the frequency of device usage to avoid downtime caused by stock shortages.
   • Model MatchingWhen replacing cables, it is necessary to ensure that the model and specifications are consistent with the original cable to avoid compatibility and potential malfunctions.

5、 Fault handling and emergency measures

1. Common faults and their solutions
   • signal interruptionCheck if the joint is loose or oxidized, reconnect and apply conductive paste; If the problem persists, the cable needs to be replaced.
   • Insulation damageImmediately stop using and isolate the faulty cable to prevent the risk of electric shock; After temporary repair with insulating tape, replace the cable with a new one as soon as possible.
   • Mechanical jammingCheck if the drag chain is deformed or if there are foreign objects inside, clean it and reinstall the cable.
2. emergency measures
   • Temporary substituteIn emergency situations, spare cables of the same specifications can be used as temporary replacements, but the operating time needs to be shortened and replaced with dedicated cables as soon as possible.
   • Safe isolationIf the cable is damaged and causes leakage, the power should be immediately cut off and warning signs should be set up to prevent personnel from touching it.